RENR8341-04

May 2011

Specifications
Systems Operation
Testing and Adjusting
793D Off-Highway Truck
Hydraulic Fan System
FDB1-Up (Machine)

SAFETY.CAT.COM
 i03991620

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR8341-04 3
Table of Contents

Table of Contents
Specifications Section
Steering Tank and Filter .......................................... 4
Pump Drive ............................................................ 4
Piston Pump (Hydraulic Fan) .................................. 5
Check Valve (Hydraulic Fan Piston Pump) ............. 8
Makeup Valve (Hydraulic Fan Motor) ..................... 8
Piston Motor (Hydraulic Fan) .................................. 8
Piston Motor (Hydraulic Fan) .................................. 9
Speed Sensor (Fan Drive) .................................... 10
Oil Filter (Hydraulic Fan, Steering) (Case Drain) .. 10
Pressure Switch (Hydraulic Fan, Steering Oil
Filter) ................................................................... 10

Systems Operation Section

Graphic Color Codes ............................................. 11
Fan Hydraulic System ........................................... 12
Steering Tank and Filter ........................................ 15
Piston Pump (Hydraulic Fan) ................................ 16
Makeup Valve (Hydraulic Fan Motor) ................... 19
Piston Motor (Hydraulic Fan) ................................ 19
Oil Cooler (Brake, Hydraulic Fan, Steering) ......... 21

Testing and Adjusting Section

Testing and Adjusting
General Information .............................................. 22
System Pressure - Release .................................. 22
Piston Pump (Hydraulic Fan) Pressure - Test and
Adjust .................................................................. 22
Piston Pump (Hydraulic Fan) - Adjust ................... 26
Pump Drive - Adjust .............................................. 26
Worksheets ........................................................... 27

Index Section
Index ..................................................................... 29
4 RENR8341-04
Specifications Section

Specifications Section i04367895

Pump Drive
i02386360
SMCS Code: 3108
Steering Tank and Filter Part No.: 271-0163
SMCS Code: 4332-FI
Part No.: 248-6246

g01190582
Illustration 1

(1) Torque for stud ............... 35 ± 5 N·m (26 ± 4 lb ft)

g01958075
Illustration 2
(2) Torque for locknut ............ 10 ± 2 N·m (7 ± 1 lb ft)
(1) Apply Loctite Gasket Maker #2 to the threads of
(3) 0L-0646 Spring
ten bolts.
Length under test force ... 66.68 mm (2.625 inch)
Test force ..... 190.2 to 210.2 N (47.25 ± 42.75 lb)
Free length after test ...... 92.08 mm (3.625 inch)
Outside diameter ............ 29.36 mm (1.156 inch)
RENR8341-04 5
Specifications Section

i04381080

Piston Pump (Hydraulic Fan)

SMCS Code: 1387-QP; 5070-HFN
Part No.: 240-7789

g01208085
Illustration 4

Pump rotation is counterclockwise when the pump is

viewed from the drive end.

Type of pump ... Variable Displacement Piston Pump

g01958077
Illustration 3
Pressure cutoff ........................ 32500 kPa (4714 psi)
Section A-A
Pump displacement ........................ 190 cc (12 cu in)
Note: Refer to the Machine Systems Disassembly
and Assembly, “Pump Drive - Assemble” for (1) 215-6758 Pressure and Flow Compensator
adjustment of the pump drive. Valve
(2) Lubricate the lip type seal lightly with the lubricant Note: Refer to “Pressure and Flow Compensator
that is being sealed. Valve” for additional information.
(3) Lubricate the O-ring seal lightly with the lubricant
that is being sealed.

(4) Thickness of the shim pack .. 2.1 mm (0.08 inch)

(5) Apply Loctite 271 High Strength thread lock to

the threads of the bolts.

(6) Thickness of the shim pack .................. 1.68 mm

(0.066 inch)
6 RENR8341-04
Specifications Section

(8) Torque for plug .......................... 25 N·m (18 lb ft)

(9) Torque for four bolts .............. 620 N·m (457 lb ft)

g01208113
Illustration 7
View of 256-3680 Pump Rotating Gp (4)

Illustration 5
g01524151 (10) 179-6916 Spring
Section A-A
Length .............................. 11.17 mm (0.440 inch)
Outside diameter .............. 5.80 mm (0.228 inch)
(2) Torque for two locknuts ......... 170 N·m (125 lb ft)
(11) 179-6914 Shim
(3) Torque for four bolts .............. 215 N·m (159 lb ft)
(12) 179-6915 Shim
(4) 256-3680 Pump Rotating Gp
(13) Torque for four bolts ......... 9 ± 2 N·m (6 ± 1 lb ft)
(5) 256-5000 Pump Head Gp
Note: Apply 9S-3263 Thread Lock Compound to the
threads of bolts (13) prior to installation.

Note: Use shims (11) and (12) in order to obtain

dimension (E) of 146.10 - 0.25 mm (5.75 ± 0.010 inch).

g01524154
Illustration 6
View B-B
Section C-C
Section D-D

(6) Torque for two plugs ............. 198 N·m (146 lb ft)

(7) Torque for four plugs ................... 10 N·m (7 lb ft)

RENR8341-04 7
Specifications Section

Pressure and Flow Compensator

Valve

g01207946
Illustration 9

(19) 216-1397 Displacement Solenoid

g01190892
Illustration 8 (20) 117-7496 High Pressure Cutoff Valve

(14) Apply 9S-3263 Thread Lock Compound to the (21) 117-7522 Spring
threads prior to assembly.
Free length ..................... 16.75 mm (0.660 inch)
(15) Torque for plug .......................... 5 N·m (44 lb in) Outside diameter ................ 2.6 mm (0.102 inch)

(16) Torque for orifice ....................... 3 N·m (26 lb in) (22) 216-0793 Flow Compensator Valve

(17) Torque for plug .......................... 3 N·m (26 lb in) (23) 170-9822 Spring
Free length ..................... 12.20 mm (0.480 inch)
(18) Torque for plug .......................... 5 N·m (44 lb in) Outside diameter .............. 1.90 mm (0.075 inch)

(24) 170-9821 Spring

Free length .......................... 47 mm (1.850 inch)
Outside diameter .............. 1.50 mm (0.059 inch)
8 RENR8341-04
Specifications Section

i02384313 i03591562

Check Valve (Hydraulic Fan Piston Motor (Hydraulic Fan)

Piston Pump) SMCS Code: 1386-QP; 5058-HFN
SMCS Code: 5067-NP; 5067-HFN Part No.: 240-7790
Part No.: 166-3438

g01917433
Illustration 12
g01189118
Illustration 10
The rotation of the shaft is bidirectional.
(1) Check valve Displacement per revolution ........... 355 cc (21.7 in3)
Cracking pressure .......... 35 ± 21 kPa (5 ± 3 psi)
(1) Motor rotating group

i04373018 (2) Torque for bolt ........ 350 ± 15 N·m (260 ± 11 lb ft)

Makeup Valve (Hydraulic Fan

Motor)
SMCS Code: 5080-FM
Part No.: 183-7170

g01917453
Illustration 13

Note: Motor Rotating Group (Fan Drive)

(A) As required, use shim kit (5) in order to obtain

g01237196
Illustration 11
(1) Tighten the plug to 245 ± 25 N·m (180 ± 18 lb ft).
(2) 7S-8491 Spring
Free length ......................... 41.1 mm (1.62 inch)
Outside diameter ................ 30.2 mm (1.19 inch)
the dimension. ....................... 148.00 ± 0.05 mm
(5.827 ± 0.002 inch)
(B) As required, use spacer kit (7) in order to obtain
the dimension. ..................... 0.25 + 0.1 - 0.0 mm
(0.010 + 0.004 - 0.000 inch)
(3) Torque for 14 bolts .................... 37 N·m (28 lb ft)
(4) 257-2156 Spring
Free length .......................... 24 mm (0.945 inch)
Outside diameter .............. 14.7 mm (0.578 inch)
RENR8341-04 9
Specifications Section

(5) 257-2173 Shim Kit (2) Torque for plug .......................... 25 N·m (18 lb ft)
Shim ................................. 7.40 mm (0.291 inch) (3) Torque for plug ........................ 127 N·m (95 lb ft)
Shim ................................. 7.45 mm (0.293 inch)
Shim ................................... 7.5 mm (0.295 inch) (4) Torque for bolt ....................... 250 N·m (185 lb ft)
Shim ................................. 7.55 mm (0.297 inch)
Shim ................................... 7.6 mm (0.299 inch)
Shim ................................. 7.65 mm (0.301 inch)
Shim ................................... 8.4 mm (0.330 inch)

(6) 191-0653 Spring

Length ............................... 93.6 mm (3.685 inch)
Outside Diameter ............ 25.24 mm (0.994 inch)

(7) 191-0666 Spacer Kit

Spacer .............................. 1.70 mm (0.067 inch)
Spacer .............................. 1.75 mm (0.070 inch)
Spacer .............................. 1.80 mm (0.071 inch)
Spacer .............................. 1.85 mm (0.073 inch) g01196451
Spacer .............................. 1.90 mm (0.075 inch) Illustration 15
Spacer .............................. 1.95 mm (0.077 inch)
Spacer .............................. 2.00 mm (0.079 inch) Note: Motor Rotating Group (Fan Drive)
Spacer .............................. 2.05 mm (0.081 inch)
Spacer .............................. 2.10 mm (0.083 inch) (5) 257-2157 Shim ................. 1 mm (0.0394 inch)
Spacer .............................. 2.15 mm (0.085 inch)
Spacer .............................. 2.20 mm (0.087 inch) (6) 257-2150 Shim Kit
Spacer .............................. 2.25 mm (0.089 inch)
Shim ............................... 7.40 mm (0.2913 inch)
Spacer .............................. 2.30 mm (0.091 inch)
Shim ............................... 7.45 mm (0.2933 inch)
Spacer .............................. 2.35 mm (0.093 inch)
Shim ............................... 7.50 mm (0.2953 inch)
Spacer .............................. 2.40 mm (0.095 inch)
Shim ............................... 8.00 mm (0.3150 inch)
Spacer ............................... 3.00 mm (0.118 inch)
(7) Torque for bolt ............... 28 ± 7 N·m (20 ± 5 lb ft)
i04373715
(8) 9T-9451 Spring
Piston Motor (Hydraulic Fan)
Test length ......................... 71 mm (2.7953 inch)
SMCS Code: 1386-QP; 5058-HFN Test force ................ 2200 ± 150 N (495 ± 335 lb)
Free length after test ...... 86.2 mm (3.3937 inch)
Part No.: 240-7790 Outside diameter ............ 22.5 mm (0.8858 inch)

(9) 257-2156 Spring

Length ................................ 24 mm (0.9449 inch)
Outside Diameter ............ 14.7 mm (0.5787 inch)

g01196298
Illustration 14

The rotation of the shaft is bidirectional.

Displacement per revolution ........... 355 cc (21.7 in3)

(1) Motor rotating group

10 RENR8341-04
Specifications Section

i01430331 (1) Base Assembly

Speed Sensor (Fan Drive) Oil filter bypass valve setting .......... 172 kPa (25 psi)
SMCS Code: 1408 (2) Torque for the pressure switch .......... 35 ± 3 N·m
(26 ± 2 lb ft)
Part No.: 186-0131
(3) Scheduled Oil Sampling Port

Note: Assemble the filter so that the arrows on filter

base point in the direction of oil flow.

i02424819

Pressure Switch (Hydraulic

Fan, Steering Oil Filter)
SMCS Code: 1408-ZS; 1435-PX; 5093
Part No.: 117-7773
g00712330
Illustration 16

Install the speed sensor until the speed sensor

contacts the gear. Rotate the speed sensor
by one-half turn in the counterclockwise
direction. Tighten the locknut to the following
torque. .................................. 25 ± 5 N·m (18 ± 4 lb ft)

i02383682

Oil Filter (Hydraulic Fan,

Steering)
(Case Drain) Illustration 18
g00888971

SMCS Code: 5068-HFN; 5068-ZH

Actuation pressure ............ 138 ± 28 kPa (20 ± 4 psi)
Part No.: 177-6979
Minimum deactuation pressure ......... 69 kPa (10 psi)

(1) Final installation torque .. 35 ± 3 N·m (26 ± 2 lb ft)

g00844325
Illustration 17
RENR8341-04 11
Systems Operation Section

Systems Operation Section (N) Red and Pink Stripes .... Second pump pressure

(O) Orange ......... Pilot, signal or torque converter oil

i01852294
(P) Orange Stripes and White Stripes ........ Reduced
Graphic Color Codes pilot, signal or torque converter oil

SMCS Code: 1359; 5050 (Q) Orange Crosshatch ............ Second reduction in
pilot, signal or torque converter oil

(R) Blue .................................................. Trapped oil

g00943660
Illustration 19

(A) Black ..................... Mechanical connection, seal

(B) Dark Gray ................................. Cutaway section

(C) Light Gray ..................................... Surface color

(D) White ............... Atmosphere or air (no pressure)

(E) Purple ................................. Pnuematic pressure

(F) Yellow .... Moving parts or activated components

(H) Green .................................................... Tank oil,

suction oil, return oil, and case drain oil

(I) Brown ............................................ Lubricating oil

(J) Red ............. High pressure oil (pump discharge)

(K) Red Stripes and White

Stripes .......................... First pressure reduction

(L) Red Crosshatch ....... Second pressure reduction

(M) Pink ............................. Third pressure reduction

12 RENR8341-04
Systems Operation Section

i04364981

Fan Hydraulic System

SMCS Code: 1386-QP; 1387-QP; 5058-HFN;
5070-HFN

Hydraulic System

g02518736
Illustration 20

Location of Components

g01203994
Illustration 21
(2) Makeup valve (fan motor) (4) Steering tank and filter (6) Fan drive pump
RENR8341-04 13
Systems Operation Section

g01278097 g01204144
Illustration 22 Illustration 25
(3) Location of the steering and fan drive oil cooler (4) Steering tank and filter
(5) Case drain oil filter for the fan drive pump and motor

g01204165
Illustration 26
(6) Fan drive pump
(10) Displacement solenoid
(11) Pressure and flow compensator
(12) High-pressure cutoff valve

g01277515
Illustration 23 Operation
(1) Fan drive motor
(1A) Speed sensor (fan drive) Oil flows from fan drive pump (6) through makeup
valve (2) to fan drive motor (1). Return oil also flows
from fan drive motor (1) through makeup valve (2) to
oil cooler (3). The return oil then flows from oil cooler
(3) to steering tank and filter (4).

Fan drive motor (1) is a fixed displacement motor.

The fan speed is determined by the amount of flow
from fan drive pump (6). Fan drive pump (6) is a
variable displacement piston pump that is controlled
by the Brake/Cooling ECM.

Case drain oil flows from fan drive motor (1) and
fan drive pump (6) through case drain oil filter (5) to
steering tank and filter (4).
g01277516
Illustration 24
If the supply oil to the fan stops suddenly, the fan
(2) Makeup valve (fan motor) and the motor may continue to rotate because of
the mass of the fan. Makeup valve (2) allows the
oil in the circuit to flow from the return side to the
supply side. This prevents a vacuum in the lines on
the supply side.
14 RENR8341-04
Systems Operation Section

Fan speed is controlled by the Brake/Cooling ECM.

Fan speed will vary depending on many inputs.

The following inputs determine the fan speed:

• Jacket water coolant temperature

• Aftercooler coolant temperature
• Transmission lubrication temperature
• Torque converter outlet temperature
• Brake oil temperature
• Brake status
• Ground speed
• Output status of the hoist system
Table 1

Standard Fan Speed Control Limits (RPM)

84 in Fan
Engine Speed Non-Retarding Retarding Fan
Fan Speed Limit Speed Limit
1250 or Less 339 525
1300 353 525
1450 394 817
1500 407 817
1600 434 817
1700 461 817
1750 or more 475 817

Refer to Table 1 for the fan speed limits that are

based on the temperature sensor inputs, the ground
speed, and the retarding/braking inputs.

Table 2
Engine Fan Control, Non-Retarding Or Retarding Below 4 MPH
84 in Fan(1)
Aftercooler Jacket Water Transmission TC Out Brake Oil Fan Control
Temperature Coolant Lubrication Temperature Temperature
Temperature Temperature
Priority 1 2 3 4 5
<65 °C (149 °F) <88 °C (190 °F) <88 °C (190 °F) <88 °C <102 °C (215 °F) Off
(190 °F)
<65 °C (149 °F) <99 °C (210 °F) <96 °C (204 °F) <102 °C <107 °C (225 °F) Modulate By Priority
>88 °C (190 °F) >88 °C (190 °F) (216 °F) >102 °C (215 °F)
>88 °C
(190 °F)
>65 °C (149 °F) >99 °C (210 °F) >96 °C (204 °F) >102 °C >107 °C (225 °F) “Limit Chart”
(215 °F)
(1) When, you use Retarding/Braking 4 mph and above 4 mph will set the fan speed to the “limit chart”.
RENR8341-04 15
Systems Operation Section

Refer to Table 2. If all of the temperature sensors are

below the lower limits, then the fan control is turned
off and the fan speed could be near 0 rpm. If the
temperatures are between the sensor's lower limits
and the sensor's upper limits, then the fan speed will
be modulated by priority. If any of the temperatures
are above the upper limits, the fan speed will be set
to the limits that are shown in Table 1.

Note: When the body is being raised or lowered, the

fan speed will be 200 rpm in order to reduce the load
on the pump drive.

i02553829

Steering Tank and Filter

SMCS Code: 4332-FI

g01278192
Illustration 28
(7) Low-engine dead switch port
(8) Case drain oil filter for the steering pump
(9) Case drain oil filter for the fan drive pump and motor
(10) Fast fill switch port
(11) Case drain return ports
g01278284
Illustration 27 (12) Steering oil temperature sensor
(13) Auxiliary power port
(1) Main filter for the steering hydraulic tank
(2) Vacuum breather port
(3) Steering hydraulic tank cap Internal leakage from the case drains of the steering
(4) Main steering return port piston pump, the fan drive pump, and the fan drive
(5) Ecology drain motor is returned to the steering hydraulic tank
(6) Steering suction port
through return lines for the case drain oil. The return
oil is then filtered through the case drain oil filter
for the steering pump (8) and the case drain oil
filter for the fan drive pump and motor (9). Next,
the case drain oil from the steering and fan drive
systems flows through ports (11) to the main filter
for the steering hydraulic tank (1). The main filter for
the steering hydraulic tank (1) is located inside the
steering hydraulic tank. Normally, oil flows through
these filters and clean oil is returned to the steering
hydraulic tank. Any debris in the oil is stopped by the
case drain oil filter for the steering pump (8), the case
drain oil filter for the fan drive pump and motor (9),
and the main filter for the steering hydraulic tank (1).
16
Systems Operation Section
Oil flows out of the bottom of the steering hydraulic
tank through several ports. Port (6) supplies oil to the
steering system and the fan system. The steering
hydraulic tank supplies oil to the steering system, the
engine cooling fan drive system, the rear axle cooling
fan drive system, the steering and fan drive oil cooler,
and the RAX lube system. The steering hydraulic
tank has two sight gauges. The top sight gauge is
generally used for checking the oil level when the
machine is off. The bottom sight gauge should be
used when the machine is running and the steering
accumulator is charged. Steering oil temperature
sensor (12) monitors the temperature of the oil in the
steering hydraulic tank.
Note: If either the case drain oil filter for the steering
pump (8) or the case drain oil filter for the fan drive
pump and motor (9) becomes full of debris, the
restriction to flow causes a pressure increase. The
case drain oil filter for the steering pump (8) and the
case drain oil filter for the fan drive pump and motor
(9) have bypass valves. The bypass valves will open
when the pressure increases to the bypass pressure.
When the bypass valve opens, oil is allowed to
bypass the filter elements. Then, the oil flows directly
into the steering hydraulic tank. When oil bypasses
the case drain oil filter for the steering pump (8) or
the case drain oil filter for the fan drive pump and
motor (9), debris in the oil will cause damage to other
system components. Proper maintenance must be
used to ensure that the filter element does not stop
the flow of clean oil to the hydraulic system.
i04381089
Piston Pump (Hydraulic Fan)
SMCS Code: 1387-QP; 5070-HFN
g01209099
Illustration 29
(1) Suction line
(2) Pressure and flow compensator valve
(3) Current adjustment screw
(4) Discharge line
(5) High-pressure cutoff valve
(6) Displacement solenoid
(7) Fan drive pump
RENR8341-04
Fan drive pump (7) is mounted to the front of the
pump drive. The pump drive is located on the inside
of the right frame rail. Oil from the steering tank
enters the pump through suction hose (1). The
charge pump keeps the fan drive pump full of oil.
The Brake ECM controls the flow of oil from the
fan drive pump (7) by energizing the displacement
solenoid (6). The coil resistance through
displacement solenoid (6) is 24 ohms. Pressure and
flow compensator (2) contains high-pressure cutoff
valve (5) and displacement solenoid (6). Current
adjustment screw (3) controls the spring pressure in
displacement solenoid (6). Current adjustment screw
(3) changes the minimum current that is required to
start destroking the pump. High-pressure cutoff valve
(5) is an adjustable valve that controls the maximum
pressure in the fan system.
Note: The settings for the high-pressure cutoff valve
must be set lower at higher altitudes.
The Brake/Cooling ECM analyzes the sensor inputs
for the various temperatures. The Brake/Cooling
ECM will send 0 to 640 mA to displacement solenoid
(6). The swashplate angle, pump flow, and fan speed
will modulate with the amount of current at the
displacement solenoid (6). At 0 to 200 mA, the pump
is at the maximum displacement and the fan speed
is at maximum speed. At 600 to 640 mA, the pump
is at the minimum displacement and the fan speed is
at minimum speed.
RENR8341-04
Illustration 30
Sectional view of the fan drive pump
(2) Pressure and flow compensator valve (10) Piston
(6) Displacement solenoid (11) Spring
(8) Swashplate (12) Actuator piston (maximum angle)
(9) Stop screw (minimum angle) (13) Impeller (charge pump)
Oil flows from the pump through a makeup valve to
the fan motors. Fan speed is controlled by controlling
the flow from the pump to the fan motors. Oil flows
from the pump to high-pressure cutoff valve (5),
displacement valve (6), and actuator piston (12).
Large spring (11) around actuator piston (12) holds
swashplate (8) at the maximum angle. Pump output
pressure is always present on the right side of the
actuator piston (12). Pump output pressure also
helps to hold swashplate (8) at the maximum angle.
When swashplate (8) is at the maximum angle, the
pump output is at the maximum flow. The fan speed
is at maximum speed. This is the position of the
pump when displacement solenoid (6) receives 0 to
200 mA from the Brake/Cooling ECM.
17
Systems Operation Section
g01278903
(14) Stop screw (maximum angle)
(15) Rotary Group
(16) Actuator piston (minimum angle)
(17) Drive shaft
When displacement solenoid (6) is receiving 200 to
640 mA from the Brake/Cooling ECM, displacement
solenoid (6) will begin to move a spool in pressure
and flow compensator valve (2) to the left. The spool
allows pump output pressure to begin to flow to
actuator piston (16). High-pressure cutoff valve (5)
controls the flow of pump output pressure to actuator
piston (16).
When system pressure is at the maximum,
high-pressure cutoff valve (5) sends more oil to
actuator piston (16). Actuator piston (16) has a larger
diameter than actuator piston (12). Actuator piston
(16) moves swashplate (8) to the position of minimum
flow. When swashplate (8) is at the minimum angle,
the pump output is at the minimum flow and the fan
speed is at minimum speed. This is the position of
the pump when the displacement solenoid receives
640 mA from the Brake/Cooling ECM.
18 RENR8341-04
Systems Operation Section

Illustration 31
(3) Current adjustment screw
(5) High-pressure cutoff valve
(6) Displacement solenoid
(12) Actuator piston (maximum angle)
g01278908
(16) Actuator piston (minimum angle) (21) Adjustment screw for the high-pressure
(18) Oil from pump supply cutoff valve
(19) Oil to actuator piston (minimum angle)
(20) Oil to drain

Before swashplate (8) contacts stop screw (9),

actuator piston (16) will open a small drain port to
the tank. This will stop the movement of swashplate
(8). Draining the oil from the actuator piston (16)
will prevent swashplate (8) from contacting stop
screw (9) repeatedly. Repeated contact between the
swashplate and the stop screw can be noisy, and the
contact may cause damage to the pump.

Stop screw (minimum angle) (9) is located near the

pressure and flow compensator valve (2). Stop screw
(maximum angle) (14) is located on the other side
of the pump.

Note: Do not adjust the minimum or maximum angle

stop screws in chassis. This adjustment should only
be done on a hydraulic test stand.
RENR8341-04 19
Systems Operation Section

i04381103 Return oil from the piston motor is used as makeup

oil. When the fan stops operating, the makeup oil is
Makeup Valve (Hydraulic Fan used to prevent a vacuum condition in the piston
Motor) motor.

SMCS Code: 5080-FM When the control valve for the piston pump signals
the piston pump to destroke, the supply of oil to the
piston motor is reduced. The piston motor continues
to rotate due to the mass of the fan blade assembly.
Continued rotation of the piston motor creates a
vacuum at passage (7) of makeup valve (1). This
vacuum lowers the pressure in passage (7). The
combined force of the pressure in passage (7) and
the force of spring (8) is less than the force of the
pressure that is in passage (4). Check valve (5) will
open.

When check valve (5) is open, return oil from passage

(4) flows to passage (7). The return oil enters the
piston motor through line (6). This makeup oil circuit
eliminates the possibility of cavitation in the piston
g01207693
Illustration 32 motor.
Makeup valve
(1) Makeup valve for the piston motor for the fan drive
The same process occurs when the machine is shut
(2) Pressure tap down.

Makeup valve (1) for the piston motor is mounted Pressure tap (2) is located on makeup valve (1).
behind the lower right section of the radiator. The pressure tap is used in order to measure the
pressure of the piston pump.

i04381106

Piston Motor (Hydraulic Fan)

SMCS Code: 1386-QP; 5058-HFN

g01278074
Illustration 33
Makeup valve for the piston motor for the fan drive
(3) Return port
(4) Passage
(5) Check valve
(6) Supply port from the cooling piston pump
(7) Passage
(8) Spring g01211859
Illustration 34
The supply oil flows from the piston pump through Back of the engine radiator
the makeup valve to the piston motor. Return oil also (1) Fan motor
flows from the piston motor through the makeup (2) Speed sensor (fan drive)
valve.
20 RENR8341-04
Systems Operation Section

Fan motor (1) is a fixed displacement axial piston

motor. The fan motor is operated by the pressure oil
from the variable displacement piston pumps. The
fan motor is directly attached to the fan.

Fan speed sensor (2) provides an input signal to the

Brake/Cooling ECM. The Brake/Cooling ECM uses
this input in order to maintain the fan speed between
0 and 817 rpm.

g00926717
Illustration 35
(3) Speed sensor (7) Center pin (11) Barrel
(4) Port to case drain (8) Port plate (12) Plate
(5) Plate (9) Shaft
(6) Piston (10) Housing

The components of the motor that turn are shaft (9),

plate (5), pistons (6), and barrel (11). The parts that
do not turn are plate (12), housing (10), and port
plate (8).

Pump oil flows through the inlet control slot in plate

(12) to port plate (8) then into the piston bores in
barrel (11). Barrel (11) rotates about center pin (7)
which is at a fixed angle of 40 degrees to the axis
of shaft (9).

The oil inside housing (10) is used to lubricate all the

bearings and the moving parts. This oil drains from
housing (10) through case drain line (2).
RENR8341-04 21
Systems Operation Section

i02402392 After the oil goes through rear brake oil coolers (2),
the oil flows to the hydraulic filter for brake cooling
Oil Cooler (Brake, Hydraulic oil. The oil then flows to the rear brakes. After the
Fan, Steering) oil flows to the rear brakes, the oil will return to the
hydraulic tank.
SMCS Code: 1365; 1374-HFN; 4346
The oil cooler relief valve for the rear brake cooling
is located in the hydraulic tank. The oil cooler relief
valve is located on the outlet line of the rear brake
cooling pump section. The relief valve prevents
excessive pressure from the gear pump. The relief
valve opens when the oil pressure exceeds the relief
pressure.

The oil cooler relief valve for brake cooling is located

on the control valve for the hoist and for the brake
cooling. The relief valve prevents excessive pressure
from the hoist gear pump. The relief valve opens
when the oil pressure exceeds the relief pressure.

g01209118
Illustration 36
(1) Oil cooler for the steering system and for the fan drive system
(2) Rear brake oil coolers

The oil cooler for the steering system and the fan
drive system is located on the right side of the
machine. Oil cooler (1) is for the steering system and
for the fan drive system. Oil coolers (2) are used to
cool the oil for the rear brakes.

Oil for the steering system and for the fan drive
system flows into the oil cooler. From the oil cooler,
the oil flows into the steering hydraulic tank.

Oil cooler (1) and oil coolers (2) are cooled by engine
coolant. Engine coolant flows from the water pump
and through the oil coolers. The engine coolant is
then returned back to the engine block.

The rear brakes are cooled by oil. The cooling oil

comes from the control valve for the hoist and for the
brake cooling. Under certain conditions, the cooling
oil also comes from the front brake cooling pump
section in the hydraulic tank.

The gear pump for the hoist sends oil to the control
valve. When the control valve for the hoist and for
brake cooling is in the HOLD position or in the FLOAT
position, the oil flows through the control valve to rear
brake oil coolers (2).

When the rear brake cooling pump section is driven,

cooling oil flows through the screen into rear brake
oil coolers (2). Refer to Systems Operation, “Machine
Electronic Control Module (Brake/Cooling)” for
information about the control for the piston pump that
drives the motor.
22 RENR8341-04
Testing and Adjusting Section

Testing and Adjusting • Tighten any fitting, any hose, or any component.
Section • Remove any fitting, any hose, or any
component.

• Adjust any fitting, any hose, or any component.

Testing and Adjusting
Before a problem can be corrected, the problem
must be identified and defined. To help identify the
i02402422 problem, refer to the following procedure.
General Information 1. To help identify the problem, refer to the
SMCS Code: 1356-HFN Troubleshooting section in this Service Manual,
“Visual Inspection”.

2. To help identify the problem, refer to the Testing

Sudden movement of the machine or release of oil
under pressure can cause injury to persons on or
near the machine.
To prevent possible injury, do the procedure that
follows before testing and adjusting the automatic
lubrication system.
and Adjusting in this Service Manual, “Automatic
Lubrication System Troubleshooting”.
3. Perform the tests in this Service Manual, “Testing
and Adjusting”.
i03619880

System Pressure - Release

NOTICE
Care must be taken to ensure that fluids are contained SMCS Code: 5050-553-PX
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to For information on releasing the system pressure,
collect the fluid with suitable containers before open- refer to Operation and Maintenance Manual, “System
ing any compartment or disassembling any compo- Pressure Release”.
nent containing fluids.
i04381113
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies Piston Pump (Hydraulic Fan)
suitable to collect and contain fluids on Caterpillar
products. Pressure - Test and Adjust
Dispose of all fluids according to local regulations and SMCS Code: 1387-036-QP; 5070-036-HFN
mandates.
The following tests cover the setting of the following
valves:
1. Move away from other operating machines and
away from personnel. Park the machine on a • Pressure and flow compensator valve
smooth, level surface.
• High-pressure cutoff valve
2. Move the transmission shift lever to the NEUTRAL
position. Engage the parking brake. Make sure Table 3
that the body is lowered. Stop the engine. Place
Required Tools
wheel chocks in front of the wheels and behind
the wheels. Part
Tool Number Part Description Qty
3. Permit only one operator on the machine. Other A 8T-0860 Pressure Gauge 1
personnel should maintain a safe distance from
the machine. All personnel should be visible to
the operator.

4. Make sure that all of the pressure in the lubrication

system and the air system is released before you
perform any of the following procedures:

• Loosen any fitting, any hose, or any component.

RENR8341-04 23
Testing and Adjusting Section

Pressure and Flow Compensator Valve

g01279726
Illustration 37
Fan drive pump
(1) Current adjustment screw
(2) Pressure and flow compensator valve
(3) Displacement solenoid
(4) High-pressure cutoff valve

Pressure and flow compensator valve (2) is mounted

to the case of the fan drive pump. The fan drive pump
is mounted to the steering pump. The steering pump
is mounted to the pump drive. The pump drive is
located on the inside of the right frame rail near the
torque converter.

The fan will overspeed if all of the following conditions

exist:

• the engine is operating at high idle.

• the setting of high-pressure cutoff valve (4) is too
high.
g01279733
Illustration 38
• displacement solenoid (3) is disconnected. (1) Current adjustment screw
(3) Displacement solenoid
A fan overspeed error occurs at approximately 895 (4) High-pressure cutoff valve
rpm. (5) Adjustment screw for the high-pressure cutoff valve

If problems are suspected, the first step is checking
the override pressure for the pump. Make sure
that the override pressure is correct. The following
procedure should be performed before running any
of the fan tests at full speed to ensure that fan
overspeed does not occur.
Note: Maximum pressures may need to be set
differently at high altitudes to avoid possible fan
overspeed and damage.
Note: There is no procedure for adjusting current
adjustment screw (1) at this time.
Note: There are two methods that can be used to
view fan speeds:
• Use the Caterpillar Electronic Technician (ET)
service tool and view the data with the VIMS
display window.
• Use the Cat ET service tool and a laptop computer
that is installed with VIMS-PC software.

1. Install the Cat ET service tool onto a laptop

computer and connect the laptop computer to the
machine in order to override the fan speed. For
more information on the use of the Cat ET service
tool, refer to the Special Instruction.

2. Start the engine.

24 RENR8341-04
Testing and Adjusting Section

3. Use the following procedure in order to configure High Pressure Cutoff Valve
a group of parameters within Cat ET service tool,
that will be monitored.

a. On the Cat ET screen, select Datalink. From

the ECM list, choose the Brake ECM.

b. From the Status Group, create a new group

that is called Fan Test.

c. The following parameters should be inserted

into the Fan Test from the Brake ECM: Desired
Engine Fan Speed, Engine Fan Speed, and
Engine Speed.

4. With cold temperatures, no service brakes and

the engine at low idle, the fan drive pump will be
at minimum displacement. The fan speed and
the fan drive pump pressure should be less than
3445 kPa (500 psi). At high idle, the fan drive
pump pressure will also be less than 3445 kPa
(500 psi).

5. The following procedure will be used to override

the fan speed. During the test, the fan speed will
be overridden at 400 rpm, 600 rpm, and 817 rpm.

Note: When the engine speed is changed from low

idle to high idle, the fan drive pump will produce
a hydraulic pressure spike while the fan begins to
rotate. The fan drive pump pressure will begin to
even out.

a. On the Cat ET screen, select Diagnostics.

Select Override Parameters.
g01279942
b. Select “Desired Engine Cooling Fan Speed Illustration 39
Override” and change the value to the required (3) Displacement solenoid
rpm. (4) High-pressure cutoff valve
(5) Adjustment screw for the high-pressure cutoff valve
(6) Locknut for the high-pressure cutoff valve
6. With the engine at low idle, override the fan speed
to 400 rpm and 625 rpm (for standard retarding In order to determine the correct high-pressure
truck). With the engine at low idle, override the cutoff setting for the altitude of the truck, follow the
fan speed to 400 rpm and 817 rpm (for additional procedure below.
retarding truck). Monitor the fan speed at each
interval and verify that the actual fan speed 1. Shut off the engine.
matches the desired fan speed.
2. Disconnect displacement solenoid (3) from
the main wiring harness. Disconnecting the
displacement solenoid will cause the fan drive
pump to upstroke and operate at maximum flow
and pressure.

3. Install Tool (A) (minimum 34500 kPa (5000 psi))

into the “M” port of the fan drive pump.

4. Start the engine. Slowly raise the engine speed

from low idle to high idle per the following
instructions:
RENR8341-04 25
Testing and Adjusting Section

a. Monitor the fan speed. During this step if the
fan speed goes beyond 670 rpm (for standard
retarding truck) or 850 rpm (for additional
retarding truck) slowly turn * adjustment screw
(5) such that the fan speed reduces to 670
rpm (for standard retarding truck) or 850 rpm
(for additional retarding truck). Continue the
adjustment process until the fan speed at high
idle is 670 rpm (for standard retarding truck)
or 850 rpm (for additional retarding truck). If
the pump cannot be adjusted back to 670 rpm
(for standard retarding truck) or 850 rpm (for
additional retarding truck) then replace the fan
high-pressure cutoff valve (4). If the problem
still exists after replacing the fan high-pressure
cutoff valve, then replace the fan drive pump.
Note: Adjustment of adjustment screw (5) should be
done with extreme care. One full turn (360 degree
rotation) of adjustment screw (5) causes about
150 bar (2175 psi) pressure change. A quarter turn
(90 degree rotation) causes about a 37.5 bar (545 psi)
pressure change. When the adjustment screw (5) is
turned too many turns, the cutoff valve will not work.
If this happens, then turning the adjustment screw
(5) clockwise or counterclockwise cannot solve the
problem. In that case the control unit must be taken
apart and then reassembled again.

Note: * Loosen locknut (6) on high-pressure cutoff

valve (4). Rotate adjustment screw (5) clockwise in
order to raise the pressure. Rotate the adjustment
screw (5) counterclockwise in order to lower the
pressure. One full turn of the adjustment screw (5)
will change the pressure setting of the fan drive
pump by 150 bar (2175 psi). Each quarter turn will
change the pressure by 37.5 bar (545 psi). In case
the adjustment screw (5) is turned too many turns
then the pressure adjustment valve will not work. If
adjustment screw (5) is turned too far, the cutoff valve
(4) cannot be adjusted by turning the adjustment
screw (5) clockwise only. When the adjustment
screw has been turned too far, the control unit must
be taken apart and reassembled again. During the
adjustment process, make sure that the fan drive
pump does not exceed the maximum cutoff pressure
of 32500 kPa (4700 psi). Lock adjustment screw
(5) in position by tightening the locknut (6). Ensure
that the fan speed does not go over 895 rpm. (Fan
overspeed error occurs at approximately 895 rpm).

b. Reduce the engine speed to low idle and then

increasing the engine speed to high idle to
verify that the fan speed returns to 670 rpm
(for standard retarding truck) or 850 rpm (for
additional retarding truck) at high idle.

c. Reconnect the displacement solenoid (3) into

the main wiring harness. Command the Cat ET
service tool to 625 rpm (for standard retarding
truck) or 817 rpm (for additional retarding
truck). Ensure that these speeds are attained.

d. Turn off the truck. Remove the pressure gauge

from (M) port of the fan drive pump and block
the port with the port plug.
26 RENR8341-04
Testing and Adjusting Section

i04381126

Piston Pump (Hydraulic Fan) -

Adjust
SMCS Code: 1387-025-QP; 5070-025-HFN

g01201989
Illustration 40

Note: This procedure will determine the length of rod
(2) that is needed to obtain dimension (B). Selection
of the correct rod is necessary for proper pump
operation.
1. Install swashplate (1) in the cradle bearings that
are located in the pump housing.
2. Position swashplate (1) at dimension (A).
Measure dimension (A) from swashplate (1) to the
centerline of shaft (4).
5. Measure dimension (B). Dimension (B) is
measured from the housing face to the centerline
of the crosshole that is located in piston (3).
6. Refer to the Fan Drive Hydraulic System
Specifications, “Piston Pump (Fan Drive)” for the
correct value for dimension (B) and for the correct
rod to use.
i01706653

3. Place rod (2) and piston (3) in the position that

Pump Drive - Adjust
is shown. SMCS Code: 3108-025
Note: Use only one rod during the procedure.
Assembly Procedure
4. Hold rod (2) and piston (3) at 90 degrees to
swashplate (1). Refer to Disassembly and Assembly, “Pump Drive -
Assemble” for final adjusting of the pump drive.
RENR8341-04 27
Testing and Adjusting Section

Cleaning Procedure
1. Before assembly, ensure that all parts are clean.
Also, ensure that all passages are free from
debris.

2. After the pump drive is fully assembled, connect

the appropriate hardware in order to power the
yoke.

3. Use SAE 10W oil at 66 °C (150 °F). The oil must

meet a minimum cleanliness of the standard ISO
16/13. Supply the oil at 12 L/min (3.2 US gpm).
Rotate the yoke at 2067 RPM for 20 minutes.

4. Check for leaks, abnormal noise, or large debris

in the drain port. Take corrective action if any of
these problems exist.

5. After this flushing procedure, the oil that is exiting

the pump drive must meet a minimum cleanliness
of the standard ISO 16/13. If the drain oil does not
meet this requirement, repeat Steps 1 through 5
until the oil meets this requirement.

i04367030

Worksheets
SMCS Code: 1356-036-HFN

Table 4
Hydraulic Fan Drive Test
Machine Model Date
Machine Serial Number Machine Hours
ECM Flash File Flash File
Date

Table 5
Hydraulic Fan Control Temperatures
Temperatures During The Test
Aftercooler Jacket Water Transmission Lube Torque Converter Brake
28 RENR8341-04
Testing and Adjusting Section

Table 6
Hydraulic Fan Speed Override Test
Fan Override Speed Actual Fan Speed Pump Pressure Actual Fan Speed Pump Pressure
At At At At
Low Idle Low Idle High Idle High Idle

None

200 rpm

300 rpm

400 rpm

500 rpm

525 rpm

625 rpm

Disconnect The
Solenoid.

Table 7
Hydraulic Fan
High Pressure Cut Off
Engine Speed at Low Idle Pump Pressure

Table 8
Hydraulic Fan Control
Hoist Lever Operation
Coolant Temp TC Temp Actual Fan
Engine Speed Hoist Lever Position Desired Fan Speed
> 88 °C (190 °F) > 88 °C (190 °F) Speed
High Idle Actual Temp Actual Temp
Raise
Neutral
or 200 rpm
No Service
Lower
Brakes
RENR8341-04 29
Index Section

Index
C T

Check Valve (Hydraulic Fan Piston Pump).............. 8 Table of Contents..................................................... 3

Testing and Adjusting ............................................ 22
Testing and Adjusting Section ............................... 22
F

Fan Hydraulic System ........................................... 12 W

Hydraulic System ............................................... 12
Location of Components .................................... 12 Worksheets............................................................ 27
Operation ........................................................... 13

General Information............................................... 22
Graphic Color Codes .............................................. 11

Important Safety Information ................................... 2

Makeup Valve (Hydraulic Fan Motor) ................ 8, 19

Oil Cooler (Brake, Hydraulic Fan, Steering) .......... 21

Oil Filter (Hydraulic Fan, Steering) (Case Drain)... 10

Piston Motor (Hydraulic Fan)......................... 8–9, 19

Piston Pump (Hydraulic Fan)............................. 5, 16
Pressure and Flow Compensator Valve............... 7
Piston Pump (Hydraulic Fan) - Adjust ................... 26
Piston Pump (Hydraulic Fan) Pressure - Test and
Adjust............................................................. 22–23
Pressure Switch (Hydraulic Fan, Steering Oil
Filter).................................................................... 10
Pump Drive.............................................................. 4
Pump Drive - Adjust............................................... 26
Assembly Procedure.......................................... 26
Cleaning Procedure ........................................... 27

Specifications Section ............................................. 4

Speed Sensor (Fan Drive)..................................... 10
Steering Tank and Filter..................................... 4, 15
System Pressure - Release................................... 22
Systems Operation Section .................................... 11
30 RENR8341-04
Index Section
RENR8341-04 31
Index Section
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